Mitsubushi MONTERO SHOGUN PAJERO Service Repair Workshop Manual 1983
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๐ท๏ธ Basic Information Identification Make: Mitsubishi Model: Montero / Shogun / Pajero Generation: First Generation (L040 series) Year: 1983 Codes Chassis Codes: L040 series (e.g., L043, L044, L047, L048, L049) ๐ Introduction Market Position Segment: Compact/Mid-size SUV (Sport Utility Vehicle) Target Audience: Off-road enthusiasts, families, general consumers seeking a versatile vehicle Competitive Analysis Key Competitors: Jeep Cherokee, Toyota 4Runner, Ford Bronco, Nissan Patrol Key Features Primary Selling Points: Off-road capability, rugged construction, versatility, reliability Value Proposition Diy Savings: Enables owners to perform their own maintenance and repairs, saving on dealership labor costs. ๐ Manual Details Coverage Areas Primary Markets: Global (markets using Montero, Shogun, Pajero designations) Vehicle Variants Covered: All models and trim levels Page Count Estimated Page Count: Extensive (exact number not specified, but implied to be comprehensive) Manual Type Type: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download ๐ Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, timing, cooling, lubrication, fuel systems Transmission: Manual and automatic transmission repair, clutch, drivetrain components Brakes: Hydraulic system, disc/drum brake components, parking brake, bleeding procedures Suspension Steering: Front and rear suspension components, shock absorbers, springs, steering gear, power steering Electrical: Wiring schematics, lighting system, ignition system, starting system, charging system, instrumentation, accessories Body Chassis: Body repair, panel replacement, interior trim, chassis frame, glass, bumpers Fuel Exhaust: Fuel tank, lines, exhaust system, catalytic converter (if applicable) HVAC: Heating, ventilation, and air conditioning system components and servicing (likely basic coverage for this era) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication points Diagnostics: Troubleshooting guides, symptom-to-cause analysis, diagnostic procedures for all major systems Repair: Step-by-step repair instructions for all components, from minor adjustments to major overhauls Rebuilds: Engine, transmission, and differential rebuild procedures Installation: Component replacement and installation guidance Technical Depth Depth: Factory-level detail, suitable for professional technicians and advanced DIYers Diagnostics Detail: Includes wiring diagrams, electrical component testing, and diagnostic flowcharts Special Tools: Lists any required special tools for specific repair procedures ๐ Manual Specifications File Format File Type: PDF Print Quality Printable: Yes, all pages are printable Image Scaling: Images can be enlarged and printed Binding Type Binding: Digital (PDF format for printing) Paper Type Paper: N/A (Digital) Compatibility Operating Systems: Windows 7, Vista (32/64-bit), XP, ME, 98, NT, 2000, Mac OS Software Requirements: Adobe PDF Reader โ๏ธ Engine Specifications Primary Engine Engine Code: 4G54 (2.6L) Displacement: 2555 cc (2.6 Liters) Configuration: Inline 4-cylinder, SOHC Bore X Stroke: 91.1 mm x 98.0 mm Compression Ratio: 8.5:1 (typical for 4G54) Fuel System: Carbureted (e.g., Hitachi or Mitsubishi carburetor) Performance Horsepower: Approx. 105-115 hp @ 4500-5000 rpm (US spec, varies by market and tuning) Torque: Approx. 135-145 lb-ft @ 2500-3000 rpm (US spec, varies) Other Engines Optional Engine Displacement: Diesel variants (e.g., 2.3L 4D55 Turbo Diesel) were also available globally. ๐ง Transmission Standard Type: 4-speed Manual Transmission Optional Type: 3-speed Automatic Transmission Features Drivetrain: Part-time 4-Wheel Drive (4WD) system with selectable 2WD/4WD High/4WD Low Transfer Case: Two-speed transfer case for enhanced off-road capability ๐ Dimensions Exterior Body Styles: 2-door (short wheelbase) and 4-door (long wheelbase) hardtop Wheelbase Short: Approx. 90.0 inches (2285 mm) Wheelbase Long: Approx. 104.3 inches (2650 mm) Weights Curb Weight Approx: 3,400 - 3,900 lbs (1540 - 1770 kg), depending on configuration ๐ก๏ธ Safety Features Ratings Crash Test Data: Limited official crash test data available for the 1983 model from modern agencies due to the era. Active Features Braking System: Front disc brakes, rear drum brakes Passive Features Seat Belts: Standard front seat belts (three-point inertia reel type likely) ๐ก Technology Features Infotainment Audio System: Basic AM/FM radio, optional cassette player. Aftermarket upgrades common. Driver Assistance ABS: Anti-lock Braking System (ABS) was not commonly available or standard on 1983 models. Connectivity Connectivity Features: None from the factory. ๐ง Maintenance Service Intervals Oil Change Interval: Typically every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions. Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection. Spark Plug Replacement: Typically every 30,000-60,000 miles (48,000-96,000 km), depending on plug type. Fluid Specifications Engine Oil Type: API SF or SG classification, SAE 10W-30 or 10W-40 recommended (consult manual for exact specs). Coolant Type: Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Transmission Fluid Manual: API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 Transmission Fluid Automatic: Dexron II or equivalent automatic transmission fluid (ATF) Brake Fluid Type: DOT 3 or DOT 4 brake fluid Known Issues Rust: Common issue for vehicles of this era, particularly in areas with road salt. Frame and body panel rust. Carburetor Tuning: Carburetors can require periodic tuning and rebuilding due to age and wear. 4Wd System Wear: Transfer case and hub wear can occur with heavy off-road use. Cooling System: Radiator, hoses, and water pump...
Limited official crash test data available for the 1983 model from modern agencies due to the era.
Active Features
Braking System:
Front disc brakes, rear drum brakes
Passive Features
Seat Belts:
Standard front seat belts (three-point inertia reel type likely)
๐ก Technology Features
Infotainment
Audio System:
Basic AM/FM radio, optional cassette player. Aftermarket upgrades common.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not commonly available or standard on 1983 models.
Connectivity
Connectivity Features:
None from the factory.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Typically every 30,000-60,000 miles (48,000-96,000 km), depending on plug type.
Fluid Specifications
Engine Oil Type:
API SF or SG classification, SAE 10W-30 or 10W-40 recommended (consult manual for exact specs).
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90
Transmission Fluid Automatic:
Dexron II or equivalent automatic transmission fluid (ATF)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Known Issues
Rust:
Common issue for vehicles of this era, particularly in areas with road salt. Frame and body panel rust.
Carburetor Tuning:
Carburetors can require periodic tuning and rebuilding due to age and wear.
4Wd System Wear:
Transfer case and hub wear can occur with heavy off-road use.
Cooling System:
Radiator, hoses, and water pump can degrade over time, leading to overheating.
๐ Vehicle History
Brand Heritage
Manufacturer Origin:
Japan
Model Evolution
Introduction Year:
The Pajero was first introduced in 1982, with the 1983 model being part of the initial production run of the first generation (L040).
First Generation Design:
Boxy, utilitarian design with a focus on off-road capability. Offered in short and long wheelbase variants.
Production
Production Period:
1982-1991 (First Generation)
๐ Awards & Recognition
Recognitions
Off Road Acclaim:
The Mitsubishi Pajero (as it was known in many markets) gained significant recognition and success in off-road rallies, including the Paris-Dakar Rally, beginning in the early 1980s, cementing its reputation for durability and capability.